Installation and Maintenance Manual

Transcription

1 and Maintenance Manual Compact CA Motors

2

3 and Maintenance Manual Compact CA EN411-14h 2008

4 Preface Preface Hägglunds Drives is one of the worlds leading manufacturers of large hydraulic Drive Systems. A leading position, made possible by unbeatable service spirit and of continuing development of both products and markets all over the world. Our drives are to be found in most industrial and marine segments, where there are extremely high demands for efficiency and reliability. Our main office and production plant is in Mellansel, Sweden and we have our own sales- and representation offices in some 40 different countries. Our high quality Drive Systems, are based upon our unique hydraulic piston motors, developed through a wealth of experience accumulated over 30 years in marine and industrial areas.today this ongoing development work has resulted in the powerful COMPACT CA industrial motor. New, as well as established technical solutions, contribute to the creation of this product. The most desirable features and operating reliability have been designed in this hydraulic motor. This manual provides necessary information for installation and maintenance of the motor. In order to find particular information, just search for the wanted section as listed in the table of contents. However, changes in the equipment may occur. We therefore reserve the right to introduce amendments in the manual as we deem necessary without notice or obligations. This and Maintenance Manual is valid for motors manufactured after For older motors please contact your nearest Hägglunds Drives representative. Original EN411-13h, 2006

5 Contents Contents 1. GENERAL Safety precautions Motor data Functional description TECHNICAL DATA Recommended charge pressure Sound from a complete installation Choice of hydraulic fluid Environmentally acceptable fluids INSTALLATION Mounting instructions Thread for mounting tool Spline Lifting methods Standing the motor on a flat surface Mounting the coupling onto the motor shaft Instruction to follow when mounting the COMPACT CA motor on a driven shaft a Fitting the torque arm to the motor b Fitting the double ended torque arm a Mounting the motor onto the driven shaft - shaft coupling b Mounting the motor onto the driven shaft - splines Removing the motor from the driven shaft Mounting the reaction point Brake MDA Brake MDA 5, 7 & Mounting MDA 5, 7 & Draining of brake cylinder Disassembly of MDA 5, 7 & Brake MDA 14 & Mounting MDA 14 & Draining of brake cylinder Disassembly and assembly of MDA 14 & Control of braking torque Motors with 2-speed valve Mounting of 2-speed valve on CA Oil connections Direction of rotation of motor shaft Motor with displacement shift valve Draining and venting the motor Flushing OPERATING INSTRUCTIONS Storage Before commissioning Commissioning Periodic maintenance Maintenance chart Axial thrust bearing Motor Filters Oil Oil inspection FAULT FINDING DECLARATION OF CONFORMITY... 46

6 General 1. GENERAL 1.1 Safety precautions It is of high importence that the Safety precautions are always followed, if you are unsure about something, please don t hesitate to contact your nearest HD-office for advice. Warning signs In this manual you will find the following signs which indicate a potential hazard, which can or will cause personal enjury or substantial property damage. Depending on the probability of the hazard, and how serious the injury or property damage could be, there are three levels of classification. DANGER is used to indicate the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored. WARNING is used to indicate the presence of a hazard which can cause severe personal injury, death, or substantial property damage if the warning is ignored. CAUTION is used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored. Application area All new and rebuild applications, should always be approved and supervised by Hägglunds personel. Mounting Carefully follow the instructions and be aware of the high weights and forces during lifting. Before starting up Before starting up new, rebuild or just worked on applications, all accessories and safety arrangements functions, should be controlled/tested. Periodic maintenance Notice the intervals in maintenance chart (4.4) and keep a record. Dismounting Carefully follow the instructions and be aware of the high weights and forces during lifting. 6

7 General 1.2 Motor data Table 1.1 Metric Displacement Motor type FULL DISPLACEMENT Max. ** Displacement Specific Rated Max.*** pressure torque speed speed Displacement DISPLACEMENT SHIFT Specific torque Rated speed Max. speed V bar i cm 3 T Nm s n rev n rev p V cm 3 i T Nm s n rev n rev rev bar min min rev bar min min CA CA CA CA CA :2 CA CA :2 CA :2 CA :2 CA CA CA CA :2 CA :2 CA Ratio Not recommended to be used in reduced displacement CA :2 CA :2 CA :2 CA :2 CA :2 CA :2 US Motor type FULL DISPLACEMENT Max. ** Displacement Specific Rated Max. *** pressure torque speed speed DISPLACEMENT SHIFT Specific torque Rated speed Max. speed V psi i in 3 T lbf ft s n rev n rev p V in 3 i T lbf ft s n rev n rev rev 1000 psi min min rev 1000 psi min min CA , CA , CA , CA , CA , , :2 CA , CA , , :2 CA , , :2 CA , , :2 CA , CA , CA , CA , , :2 CA , , :2 CA , CA , , :2 CA , , :2 CA , :2 CA , , :2 CA , , :2 CA , , :2 Ratio Not recommended to be used in reduced displacement * Related to a required charge pressure of 12 bar/175 psi for motors in braking mode. (Special considerations regarding charge pressure, cooling and choice of hydraulic system for speeds above rated, 4 ports must be used). ** The motors are designed according to DNV-rules. Test pressure 420 bar/6000 psi. Peak/transient pressure 420 bar/6000 psi maximum, allowed to occur times. *** Speed above 280 rpm requires viton seals. Max permitted continues case pressure is 2 bar. 7

8 General 1.3 Functional description Hägglunds hydraulic industrial motor COM- PACT CA is of the radial-piston type with a rotating cylinder block/hollow shaft and a stationary housing. The cylinder block is mounted in fixed roller bearings in the housing. An even number of pistons are radially located in bores inside the cylinder block, and the valve plate directs the incoming and outgoing oil to and from the working pistons. Each piston is working against a cam roller. When the hydraulic pressure is acting on the pistons, the cam rollers are pushed against the slope on the cam ring that is rigidly connected to the housing, thereby producing a torque.the cam rollers transfer the reaction force to the piston which are guided in the rotating cylinder block. Rotation therefore occurs, and the torque available is proportional to the pressure in the system. Fig. 1 The COMPACT CA motor Oil main lines are connected to ports A and C in the connection block and drain lines to ports D1, D2 or D3 in the motor housing. The motor is connected to the shaft of the driven machine through the hollow shaft of the cylinder block.the torque is transmitted by using a mechanical shaft coupling, or alternatively by splines. The symmetrical design of the motor has made it possible to design it as a two displacement motor. This means that two different speeds can be obtained for a given flow. The simplest way of performing displacement change is by connecting a special valve, direct to the flange face on the connection block. Valid patents US , US A, SE , EP , JP , GB , EP NL , EP:DE Quality To assure our quality we maintain a Quality Assurance system, certified to standard ISO 9001, EN and BS 5750; Part D A, C F Cam ring 2. Cam roller 3. Piston 4. Shaft coupling 5. Cylinder block / hollow shaft 6. Cylinder block / spline 7. Front end cover 8. Cylindrical roller bearing 9. Connection block 10. Valve plate 11. Axial bearing A = inlet or outlet port»a«c = inlet or outlet port»c«d = drain port F4 = Flushing 8

9 2. TECHNICAL DATA 2.1 Recommended charge pressure The hydraulic system must be such that the motor will recieve sufficient charge pressure at the low-pressure port. This applies to all types of installations. There are three distinct cases: Case 1: The motor works in braking mode. Required charge pressure at the inlet port is according to diagram below. Case 2: Technical data The motor works in driving mode only. Required back pressure at the outlet port corresponds to 30% of value given in diagram below, but may not be lower than 2 bar (29 psi). In hanging load applications, charge pressure at motors connection must be according to graph below under all conditions. Case 3: The motor is used with 2-speed valve. Required charge pressure at inlet port for valve is according to AC-3.1 Accessories. Table 2.1 Charge pressure RECOMMENDED CHARGE PRESSURE - COMPACT CA MOTORS Double port connection (4 ports) oil viscolisty 40 cst / 187 SSU 20 CA 210 CA CA CA 140 CA 70, CA 100, CA CA 50, CA CA , CA CA 70-50, CA CA CA CA CA Recommended charge pressure (bar) CA CA CA CA Recommended charge pressure (psi) 2 Note: Compact motors Double port connection (4 ports) Speed (rpm) The diagram is valid for 1 bar (15 psi) case pressure. With increasing case pressure the charge pressure must be increased accordingly. The graph is valid when 4 ports are used. Max casing pressure is 3 bar (43,5 psi)(for 1% of the operation time evenly divided, pressure peaks of max 5 seconds upto 8 bar (116 psi) is allowed). Max permitted case pressure at stand-still is 8 bar (116 psi). 9

10 Technical data 2.2 Sound from a complete installation Background noise Pump motor Pipe noise Hydraulic motor Noise from driven unit Foundation and construction noise Remarks: Background noise The background noise can not normally be influenced but is usually known or easy to measure. Pump unit The pump unit is a known noise level. Pipe noise The pipe noise is probably the source of the majority of mistakes in installations: all pipe clamps should be of vibration insulating type secured to concrete ceiling, wall or floor. Securing to non-rigid metal structures or structures is likely to give resonance and should be avoided. Hydraulic motor The hydraulic motor is a known noise level. (Tables of sound data - see subsection 4.9 in the Engineering Manual). Driven unit The driven unit is an unknown sound source (for us) but can through certain information probably be obtained from the supplier. When securing the torque arm of a hydraulic motor to the foundation or casing of a driven machine, it is highly important to study the construction of the foundation or casing. This may well be the most important factor to consider, since many structures may give rise to resonance, resulting in severe noise problems. 10

11 Technical data 2.3 Choice of hydraulic fluid The Hägglunds hydraulic motors are primarily designed to operate on conventional petroleum based hydraulic oils. The hydraulic oil can be chosen in consultation with the oil supplier of your local sales office, bearing the following requirements in mind: GENERAL The oil shall have FZG (90) fail stage minimum 11 described in IP 334 (DIN 51354). The oil must also contain inhibitors to prevent oxidation, corrosion and foaming. The viscosity of mineral oil is highly dependent of the temperature. The final choice of oil must depend on the operating temperature that can be expected or that has been established in the system and not in the hydraulic tank. High temperatures in the system greatly reduce the service life of oil and rubber seals, as well as resulting in low viscosity, which in turn provides poor lubrication. Content of water shall be less than 0,1%. In Industrial applications with high demands for service life, the content of water shall be less than 0,05%. RECOMMENDED VISCOSITY AT OPERATING TEMPERATURE cst/ SSU. FOR SPEED BELOW 5 RPM, COATED PISTONS OR HIGH VISCOSITY SHALL BE USED. Viscosity index Min. permitted in continuous duty Min. permitted in intermittent duty Max. permitted Viscosity limits = 100 recommended = 150* for operation with large temperature difference 40 cst/187 SSU 20 cst/98 SSU** cst/48000 SSU Temperature limits Normal operating temperature should be less than +50 C (122 F) Nitrile seals (std motor) Viton seals Nitrile seals (std motor) Vition seals -35 C to +70 C -20 C to +100 C -31 F to +158 F -4 F to +212 F * Many hydraulic fluids with VI-improvers are subject to temporary and permanent reductions of the viscosity. ** Low viscosity gives reduced service life for the motors and reduction of max. allowed power for "COMPACT CA". Fire resistant fluids OPERATING WITH FIRE RESISTANT FLUIDS The following fluids are tested for Hägglunds motors: (ISO/DP 6071) Fluid Approved Seals Internal paint HFA: Oil (3-5%) in water emulsion No - - HFB: Inverted emulsion 40-45% water in oil Yes Nitrile (std motor) Not painted* HFC: Water-glycol Yes Nitrile (std motor)** Not painted* HFD synthetic fluids HFD:R - Phosphate esters Yes Viton Not painted* HFD:S - Chlorinated hydrocarbons Yes Viton Not painted* HFD:T - Mixture of the above Yes Viton Not painted* HFD:U - Other compositions Yes Viton Not painted* * Must be specified in the order. **The motor must have synthetic oil for the axial bearing. IMPORTANT! Down rating of pressure data and service life must be considered when using fire resistant fluid. The Hägglunds company or its authorised representative must always be contacted for approval in the case of these types of fluids. 11

12 Technical data Environmentally acceptable fluids Fluid Approved Seals Internal paint Vegetable */** Fluid HTG Yes Nitrile (std motor) - Synthetic **/*** Esters HE Yes Nitrile (std motor) - * Vegetable fluids give good lubrication and small change of viscosity with different temperature. Vegetable fluids must be controlled every 3 months and temperature shall be less than +45 (113 F) C to give good service life for the fluid. ** Environmental acceptabel fluid gives the same servicelife for the drive, as mineral oil. *** The fluid shall have less than 10g/100g according to ASTMD /DIN Filtration The oil in a hydraulic system must always be filtered and also the oil from your supplier has to be filtered when adding it to the system. The grade of filtration in a hydraulic system is a question of service life v.s. money spent on filtration. In order to obtain stated service life it is important to follow our recommendations concerning contamination level. When choosing the filter it is important to consider the amount of dirt particles that the filter can absorb and still operate satisfactory. For that reason we recommend a filter with an indicator that gives a signal when it is time to change the filter cartridge. Filtering recommendations Before start-up, check that the system is thoroughly cleaned. 1. In general the contamination level in our motors should not exceed ISO /15. (NAS 10) 2. For heavy-duty industrial applications the contamination level should not exceed ISO /13. (NAS 7) 3. When filling the tank and motor housing, we recommend the use of a filter with the grade of filtration ß10=75. Explanation of "GRADE OF FILTRATION" Grade of filtration ß10=75 indicates the following: ß10 means the size of particle 10µm that will be removed by filtration. =75 means the grade of filtration of above mentioned size of particle. The grade of filtration is defined as number of particles in the oil before filtration in relation to number of particles in the oil after filtration. Ex. Grade of filtration is ß10=75. Before the filtration the oil contains N number of particles 10µm and after passing the filter once the oil contains N number of particles 75 10µm. N N = 74 N This means that number of particles have been filtered (=98,6%). 12

13 3. INSTALLATION If the motor is to work properly it must be installed with the greatest possible precision. Every item connected to the motor that does not meet the requirements of the following instructions may result in stresses that adversely affect the service life of the motor. Normally the motor must be completely filled with oil. When the motor is installed with the shaft in the horizontal plane, the drain ports must be positioned vertically. The higher of the two drain ports must be used: see fig When the motor is mounted with the shaft in the vertical plane, drain outlet D1 or D2 must be connected to the drain hole on the shaft end housing or end cover. A preloaded check valve must be connected in the drain line to ensure that the motor is filled with oil; see "Draining and venting the motor". The drain line must be dimensioned so that max. 3 bar (43.5 psi) motor housing pressure is not exceeded. The max housing pressure is 3 bar (43.5 psi). Brief peaks during operation up to 8 bar (116 psi) are permissible. The permitted housing pressure when the motor is stationary is 8 bar (116 psi). The motor must always be connected in such a way as to give a sufficient boost, make-up flow at the low pressure connection. This is particularly important at high speeds and with rapid reversing, see 2.1 "Recommended charge pressure". 3.1 Mounting instructions Design of driven shaft end on heavilyloaded shaft Where the driven shaft is heavily loaded and is subject to high stresses, for example on changes in the direction of rotation, it is recommended that the driven shaft should have a stress relieving groove; see Fig. 3.1 and tables 3.1 and 3.4. Fig. 3.1 Normally-loaded shaft In drives with only one direction of rotation where the stresses in the shaft are moderate, the shaft can be plain, see Fig. 3.2 and tables 3.1 and 3.4 Fig. 3.2 A D 30 6±0,5 (0,24±0,02) F G F E B±0,5 (B±0,02) G Max. Ra 3,2 C Max. R 3,2 a R 50 (R 1,97) A D Table 3.1 Valid for couplings 30 E Dim CA50/70 CA100/140 CA210 0 A mm 120-0,025 0 in 4,7244-0, , ,2992 B mm in C mm in 71,5 2, ,57 84,5 3, ,24 0-0, , , ,02 Note! The dimensions are valid for +20 C (68 F) 0-0, ,00098 Table 3.2 6±0,5 (0,24±0,02) Unidirectional drives Steel with yield strength Rel = 300 N/mm Bidirectional drives Steel with yield strength Rel = 450 N/mm 13

14 Spline The splines shall be lubricated with hydraulic oil, or filled with transmission oil from the connected gearbox. To avoid wear in the splines, the installation must be within the specified tolerances in fig If there is no radial or axial force on the shaft, the shaft can be oiled only. For production of the shaft, see , , , , , , , and For control of spline see table 3.3. Thread for mounting tool To make it easier to mount the motor on the driven shaft end or to remove the motor from the shaft it is recommended that a hole (Table 3.4) should be drilled and tapped in the centre of the shaft for a mounting tool; see "Mounting the motor onto the driven shaft", and "Removing the motor from the driven shaft". The tool has both a UNC thread and a metric thread, so that the hole can be drilled and tapped to conform to one of the two alternatives given in table 3.4. Unidirectional drives Steel with yield strength Rel mm = 450 N/mm 2 Bidirectional drives Table 3.4 Alternative thread (Fig.3.1 and 3.2) Steel with yield strength Rel mm = 700 N/mm 2 CA Table 3.3 D E F G M20 >17 (0,67) 25 (0,98) 50 (1,97) UNC 5/8" >13,5 (0,53) 22 (0,87) 30 (1,18) Motor CA50/70 CA100/140 CA210 Tooth profile and bottom form DIN 5480 DIN 5480 DIN 5480 Tolerance 8f 8f 8f Guide Back Back Back Pressure angle Module Number of teeth Pitch diameter Ø 110 Ø 130 Ø 140 Minor diameter Ø 109 Ø 129 Ø 139-1,62-1,62-1,62 Major diameter Ø 119 Ø139 Ø 149-0,220-0,250-0,250 Measure over -0,083-0,085-0, , , ,961 measuring pins -0,147-0,150-0,150 Diameter of measuring pins Addendum modification X M Ø 10 Ø 10 Ø 10 +2,25 +2,25 +2,25 Fig 3.3 0,15 A (0.006) A Ø 0,2 A (0.008) Øi 14

15 3.1.1 Lifting methods Always make sure where the centre of gravity is before any lifting. Note: Motor lifted without coupling fitted, danger of slipping off. Fig. 3.4a Fig. 3.4b Steel eye bolts. (3xM12) Max Note: The End cover and screws must be removed before mounting the Steel eye bolts. After the lift refit the End cover and screws with torque 81 Nm (59 lbf. ft). Fig 3.4d (CA 210) 1 Steel eye with bolt. Fig. 3.4c Lifting the torque arm Fig. 3.5 Always make sure where the centre of gravity is before any lifting. Never stand below a hanging motor or torque arm. 15

16 Lifting Compact Tandem motor Lifting method Fig. 3.4c Oiling of splines with hydraulic oil. Fill up to plug G3/4". 90 Nm / 65 lbf. ft. Always make sure where centre of gravity is before any lifting. Never stand below the motor during lifting. See 3.1 Mounting instructions. Data for the Tandem motor Tandem motor * See Engineering Manual AC-3.5 Max. pressure bar (psi) 16 Max. speed rpm Total weight Spline version kg (lb) Total weight Shaft version kg (lb) CA50 XB0NH + TA5 + CA50 SA0N 245 (3552) (878) 427 (936) CA70 XB0NH + TA5 + CA50 SA0N 205 (2972) 429 (944) 456 (1003) 240 CA70 XB0NH + TA7 + CA70 SA0N 175 (2538) 462 (1016) 489 (1076) CA100 XB0NH + TA5 + CA50 SA0N 325 (4712) 489 (1076) 534 (1175) CA100 XB0NH + TA7 + CA70 SA0N 290 (4205) (1148) 567 (1247) CA100 XB0NH + TA10 + CA100 SA0N 245 (3552) 638 (1404) 683 (1503) CA140 XB0NH + TA5 + CA50 SA0N 260 (3770) 529 (1164) 571 (1256) CA140 XB0NH + TA7 + CA70 SA0N 235 (3408) 562 (1236) 604 (1329) 220 CA140 XB0NH + TA10 + CA100 SA0N 205 (2972) 678 (1492) 720 (1584) CA140 XB0NH + TA14 + CA140 SA0N 175 (2538) 718 (1578) 760 (1672) CA210 XB0NH + TA5 + CA50 SA0N 280 (4060) 619 (1362) 680 (1496) CA210 XB0NH+ TA7 + CA70 SA0N 260 (3770) 652 (1434) 713 (1569) CA210 XB0NH + TA10 + CA100 SA0N 235 (3408) 768 (1690) 829 (1824) 115 CA210 XB0NH + TA14 + CA140 SA0N 210 (3045) 808 (1778) 869 (1912) CA210 XB0NH + TA21 + CA SA0N 190 (2755) 898 (1976) 959 (2110) CA210 XB0NH + TA21 + CA210 SA0N 175 (2538) 898 (1976) 959 (2110) Max.torque to driven shaft* Nm (lbf ft) (18000) (36100) (54200)

17 Table 3.5 Motor Motor with shrink disc Motor with splines kg lb kg lb CA CA CA CA CA Standing the motor on a flat surface When the motor is placed on a flat surface such as a floor, it must stand either on its outer diameter or on the suitably protected end face of the hollow shaft (see Fig. 3.6 and 3.7). Fig. 3.6 Table 3.6a Torque arm TCA 5 TCA 7 TCA 10 TCA 14 kg Weight lb Support Fig. 3.7 Table 3.6b Brake MDA 5-10 MDA BICA 13 BICA 24 BICA 37 kg Weight lb Support Lifting straps must be chosen with reliable saftey margin over the total weight of the lifted object. NOTE: The motor must not be placed on the end face of the hollow shaft when the coupling is fitted, since this may cause damage to the coupling. When in storage, the motor must always be placed on the end face to the hollow shaft. It is also advisable to provide supports at the mounting surface of the motor; see Fig

18 3.1.2 Mounting the coupling onto the motor shaft Instruction to follow when mounting the COMPACT CA motor on a driven shaft Before the motor is mounted there are some preconditions which must be fulfilled: - The shaft material for the driven shaft must be of a quality which meets the minimum requirements specified by Hägglunds. (See our recommendations, table The shaft must have the dimensions as recommended in the section You should note that the couplings are from the factory lubricated with MoS 2 (Molycote) on the conical surfaces and the bolts. This lubricants shall remain on those surfaces but: Molycote must under no circumstances be transferred to the surfaces between the driven shaft and the motor. It is therefore important that you clean your hands free from Molycote. If those conditions are fullfilled you may start the mounting. - Clean the driven shaft and the out- and inside of the Compact CA motor hollow shaft. Use acetone or similar. - Remove the spacers between the two clamping rings of the coupling. - Mount the coupling on the hollow shaft of the motor. The coupling must be pushed right up to the stop of the shaft. - Mount the motor onto the driven shaft by following the instruction in the section "Mounting the motor onto the driven shaft". (With or without using the mounting tool). Never tighten the coupling screws until the motor has been mounted onto the driven shaft. However for the tightening of the coupling screws the following must be observed: Keep tension in your lifting wires to avoid a skew setting of the motor on the shaft during the tightening of the screws. Wobbling caused by a skew setting of the motor gives extra forces on the main bearings. In order to avoid the misalignment of the two clamping rings during the screw tightening, the gap between the rings must be measured in several places during the process, see Fig The difference between the measured gaps must never vary more than 1 mm (0,04") during any stage of the tightening process. Pre-set the coupling screws in opposite pairs ( o clock) until you reach max. 50% of the torque specified for the screws. It is very important that when you reach this stage the misalignment is controlled as described above. Mark the screw head (at 12 o clock) with a pen or paint so that you can follow the turning sequence of the screws. Set the torque wrench for the specified maximum torque. Tightening torque of the coupling screws; see the sign on the coupling, or table 3.9. Now start tightening the screws in sequence shown in Fig. 3.14a. Keep on doing this until you have reached the stated torque. Several passes are required before the screws are tightened to specified torque. Keep checking the alignment of the coupling. (15-20 passes may be necessary). When the specified torque is reached it is important that all screws are tightened with specified torque and that no further movement can be observed. 18

19 Remember: The following factors are important for successful mounting: - Right material and dimension on the driven shaft. - The conical surface between the coupling ring and the clamping rings + the bolts shall be coated with MoS 2 (Molycote), see Fig. 3.8.This is done from the factory at delivery! When a motor has been in for overhaul or service and shall be reassembled it may be necessary to relubricate those surfaces with Molycote again but remember only the specified surfaces! - Absolutely No Molycote on the surfaces between shaft-motor. Clean the driven shaft and the inside of the motor hollow shaft. - Alignment of the motor on the shaft. (Dimensional check). - Minimum variation in the gap between the clamping rings (Dimensional check). - Right torque on the bolts. (Use torque wrench). Fig. 3.8 Clamping rings Seal Coupling ring Washer = Coated surface Cleaned surface Before starting the motor, check that the rotating coupling can not cause damage. 19

20 3.1.3a Fitting the torque arm to the motor The torque arm is fitted to the motor before the motor is mounted on the driven shaft. - Open the nuts M16 screws for CA Clean the spigot surface on the torque arm and motor. - Oil the screws. - Make sure that the torque arm will be pointing in the right direction when the motor is mounted in place on the machine. To achieve the highest possible oil level in the motor housing, the motor must be turned until the drain outlets are positioned according to fig Line up the torque arm on the motor by using the screws with washers. - Mount screws and washers according to fig. 3.9 and screws according to fig 3.9a. - Tighten the screws to the torque stated in the table below. Fig. 3.9 CA 50/70 Fig. 3.9a CA 100/140/210 Do not weld, drill, grind or carry out any similar work on the torque arm without Hägglunds approval. Table 3.7a Motor CA 50 CA 70 CA 100 CA 140/210 Screw dimension M16 Strength class 10.9 M16 Strength class 10.9 M20 Strength class 10.9 M20 Strength class 10.9 Number of screws Tightening torque Nm lbf ft Note: Use torque wrench and oiled screws! 20

21 3.1.3b Fitting the double ended torque arm Remark! Start the system and run it for some minutes. Vent the cylinder from air. Use the vent screws on the cylinder (pos 4). The torque arm is fitted to the motor before the motor is mounted on to the driven shaft. See 3.1.3a "Fitting the torque arm to the motor". Check and adjust the rod end (pos 1) according to the drawing. Mount the rod to the torque arm, use the shaft (pos 2) and lock them with circlips. Tighten the 4 pcs of screw (pos 3) on the rod end, Torque according to table 3.7b. Fig. 3.9b A A B 1 This is valid with the cylinder on the right side hand-side of the the motor, and a single speed motor. C 3 2 Table 3.7b Cylinder Screw dimension Tightening torque Nm lbf ft 50/36 M8x /56 M10x /70 M12x /90 M16x C A Mount the hydraulic cylinder. The piston rod has to be mounted upwards, and on the right hand viewed from the motors main connection side. Cylinders oil connection A, B and C must point in the direction to the motor. Mount the hoses. The hose mounted to the high pressure connection (C) has to be mounted to the hydraulic cylinders connection B, and the hose from connection (A) has to be mounted to the cylinders connection A. 21 4

22 3.1.4a Mounting the motor onto the driven shaft - shaft coupling The motor can be mounted onto the driven shaft with or without a mounting tool, but the use of a mounting tool is recommended since it makes the work easier. It is important to arrive at the correct clamping length between the driven shaft and the hollow shaft of the motor. Ensure that the full clamping length is used by, for example, measuring and marking the driven shaft. This is of particular importance if the duty is so severe that a stress relieving groove has been made on the driven shaft. See Fig. 3.11, 3.11a and the table 3.8. Mounting the motor with a mounting tool (Fig. 3.10) - Remove the End cover together with screws and washers. - Align the motor with the driven shaft. - Locate the existing plastic washer between the nut on the mounting tool and the bearingretainer. Pass the mounting tool through the centre of the motor, and screw it into the driven shaft to stated depth by using the key handle in the end of the tool. - Pull the motor onto the shaft by turning the nut on the mounting tool until the length stated in the table 3.8, is obtained; see Fig Tightening the shaft coupling see table Remove the mounting tool. - Refit the plug. - Refit the end cover and tighten the screws together with washers. Torque 81 Nm (59 lbf ft). Fig Mounting the CA Plastic Washer Nut Mounting tool 22

23 Fig Without stress relieving groove Fig D1 B +5 0 ( B +0,2 0 ) D2 Vertical line Fig. 3.11a With stress relieving groove Mounting the motor without a mounting tool B +5 0 B +0,2 0 ( ) The motor can be mounted onto the driven shaft without using a mounting tool, though this is more difficult and takes longer time. However, it is easier to mount the motor if during mounting the compressed air trapped within the hollow shaft is evacuated. To do this, remove the End cover as described in "Mounting the motor with a mounting tool" Table 3.8 Align the motor with the driven shaft using an overhead crane or lifting truck and press it carefully onto the shaft so that the length stated in the table beside is obtained, see Fig Motor CA 50 CA 70 CA 100 CA 140 CA 210 B mm 71,5 71,5 84,5 84,5 105 Lenght B in 2,81 2,81 3,33 3,33 4,13 To achieve the highest possible oil level in the motor housing, the motor must be turned until the drain outlets are positioned according to fig

24 Fig Clean the driven shaft and the inside of the motor hollow shaft. 5 9 Table 3.9 Motor type Note 1 Uncoated screws greased with MoS 2. Note 2 Note 3 No of screws Screw dim Strength class Tightening torque Nm There is a metallic sign on every coupling with a tightening torque stamped on it. This torque is always to be used. Tightening torque value is critical. Use calibrated torque wrench. lbf ft Type of head CA 50/70 8 M16 x Hexagon CA 100/ M16 x Hexagon CA M16 x Hexagon Fig Fig. 3.14a

25 A b Mounting the motor onto the driven shaft - splines o-ring If oil here, it can be used for the spline. Then take away the o-ring. Mounting kit Oil to be filled before tightening G1 plugg Flange mounted motors For flange mounted motors, the spline shall normally not be subject to radial load.with no radial load, the splineshaft can be oiled before mounting the motor. If the motor is subject to radial load, the splines shall be filled up with oil. - Lubricate and install o-ring at leading edge of motor bore. - Check shaft/splines for burrs and lubricate shaft/ splines. - Mark spline tooth location on outside of motor bore to assist alignment during installation. - Mount the motor on to the shaft. - Bolt the motor to the flange. - Fill up hydraulic oil to the G1 plug. - Torque the G1 plug. M V =125 Nm/90 lbf. ft. - Mount the cover. M V =81 Nm/59 lbf. ft. Torquearm mounted motors o-ring Mounting kit (0,4) during filling of oil ANNICA _ Oil to be filled before tightening bolt M20 L=100 mm Motors that carry radial load, must have the splines oiled. The motor can be used for horizontal mounting and mounting with motor shaft pointing downwards. - Mount torque arm to motor with bolts supplied. Align with oil connection ports as required. - Lubricate and install o-ring at leading edge of motor bore. - Check shaft/splines for burrs and lubricate shaft/ splines. - Mark spline tooth location on outside of motor bore to assist alignment during installation. - Mount the motor on to the shaft. - Fill up hydraulic oil to the G1 plug. - Mount special designed bolt. - Torque the bolt. M V =385 Nm/280 lbf. ft. - Mount the cover. M V =81 Nm/59 lbt. ft. 25

26 ANNICA A3 _ o-ring Mounting kit Oil to be filled before tightening bolt M20 L=100 mm Torquearm mounted motors with brake Motors with brake MDA, must have the brake disassembled. See Mount torque arm to motor with bolts supplied. Align with oil connection ports as required. - Lubricate and install o-ring at leading edge of motor bore. - Check shaft/splines for burrs and lubricate shaft/ splines. - Mark spline tooth location on outside of motor bore to assist alignment during installation. - Mount motor with brake housing on the shaft. - Fill up hydraulic oil to the G1 plug. - Mount special designed bolt. - Torque the bolt. M V =385 Nm/280 lbf. ft. - Mount the brake according to Mounting kit Oil to be filled before tightening bolt M20 L=100 mm Torquearm mounted motors with brake Motors with brake BICA, must have the screwed center cover disassembled. See and Maintenance Manual for BICA - Mount torque arm to motor with bolts supplied. Align with oil connection ports as required. - Lubricate and install o-ring at leading edge of motor bore. - Check shaft/splines for burrs and lubricate shaft/ splines. - Mark tooth location on outside of motor bore to assist alignment during installation. - Mount motor with brake on the shaft. - Fill up hydraulic oil to the plug G1". - Mount special designed bolt. - Torque the bolt. M V =385 Nm/280 lbf. ft. - Mount the screwed center cover and torque the bolts. M V =24 Nm/18 lbf. ft. 26

27 3.1.5 Removing the motor from the driven shaft Before dismounting the motor from the driven shaft the oil in the motor housing must be drained through the lower draining hole. The motor can be removed from the shaft with or without the mounting tool. The operation is easier if the tool is used. Never stay below the motor during disassembly Always make sure that the lifting equipment is strong enough to handle the weight of the motor Fig Removal of Compact Removal by using the mounting tool - Slacken the shaft coupling screws gradually; see Fig and 3.14a. Each screw should be slackened only about a quarter of a turn each time. Thus tilting and jamming of the collars or thread stretching will be avoided. The screws must be slackened until the coupling ring is fully released. - Remove the End cover and Bearing retainer together with screws and washers; see Fig Locate the existing plastic washer outside the mounting tool nut.then pass the tool through the centre shaft, and screw it into the driven shaft to stated depth. - Screw in the nut of the tool until the Bearing retainer can be refitted. - Remove the motor from the driven shaft by unscrewing the nut of the mounting tool. - Remove the Bearing retainer and mounting tool. Finally, refit the removed Bearing retainer, torque 136 Nm (100 lbf ft) and End cover, torque 81 Nm (59 lbf ft) as before. Removing the motor without using the mounting tool - Slacken the screws of the shaft coupling, see above "Removal of motors by using the mounting tool". - Remove endcover and plug to allow air to enter the space in the hollow shaft of the motor; see Mounting the motor without a mounting tool. After removal of the motor, refit the removed components as before. - Carefully pull the motor off the driven shaft supported by an overhead crane or a lifting truck. 1; Bearing retainer 2; Plastic Washer 3; Nut 4; Mounting tool 27

28 3.1.6 Mounting the reaction point Fig Mounting of pivoted attachment x = ±2 mm (0,079) misalignment in installation. x ±15 mm (0,59) movement when in use. ± 25 Note: The toggle bearing must be dismounted during welding. Alternative position Steel: EN 10113S355N DIN St E39 BS 4360 Grade 50 C 10 Protected against corrosion, after welding. x Fig Fig DANGER ZONE In case of failure of torque arm installation Bearing fitted with Loc-Tite 601 Make sure that the foundation can withstand the forces from the torque arm. 28

29 3.1.7 Brake MDA The brake is of the fail safe multi disc type. During normal operation hydraulic pressure keeps the discs within the brake separated, allowing shaft rotation. If hydraulic pressure is lost, springs force the discs together, stopping rotation of the shaft. The brakes are designed to operate on conventional petroleum based hydaulic oils. Fire resistant fluids HFB and HFC are not allowed. - The brakes are fatigue resistant for a braking force corresponding to 67% of braking torque. - The brake is fatigue resistant for a brake release pressure of 25 bar (360 psi). - The brake is intended to be used as a parking brake or emergency brake. - To be used as emergency brake for hanging loads, the brake must be closed very quickly. If the brake is used in cold environment as emergency brake, it must be flushed. Max allowed pressure 50 bar (750 psi). - The hydralic connection must be on top of the brake, to avoid air. Air gives a slow function for the brake Brake MDA 5, 7 & 10 Fig F3 Fig (0,83) BSP 3/4" 54 (2,1) B1 and B2 F4 F3, F4 Flushing connection BSP 1/4" Brake Motor MDA 5 CA 50 MDA 7 CA 70 MDA 10 CA 100 CA 140 CA 210 Braking torque* Begins to open at** Fully open at** Rec. opening pressure Displ. Max allowed pressure Weight Nm (lbf ft) bar (psi) bar (psi) bar (psi) cm 3 (in 3 ) bar (psi) kg (lbs) (16 100) (21 700) (29 100) 16 (230) 16 (230) 16 (230) 19 (275) 19 (275) 19 (275) ( ) ( ) ( ) 96 (5,9) 134 (8,2) 192 (11,7) 50 (725) 50 (725) 50 (725) 100 (220) 100 (220) 100 (220) * Valid at wet running. Friction coefficient µ = 0,12. Pressure in Brakecylinder = 0 bar. Hydraulic oil with AW-additives. ** See diagram 3.1. High pressure reduce service life for seals and axial bearing. 29

30 3.1.9 Mounting MDA 5, 7 & 10 The brake is normally mounted on the motor at the factory. If the brake is disassembled and shall be mounted on a motor, it must be done according to following. 1. Control that seal and Seal retainer (25) is mounted according to Fig Mount Disc center (302) on the cylinderblock. Oil the screws (43) and assemble with torque 136 Nm (100 lbf. ft). 3. Put the Brake housing (305) on the motor, and mount the right spacer (3xx). Oil the screws and mount them with tightening torque 136 Nm (100 lbf. ft). See table Mount first one outerdisc. Then mount inner disc, outerdisc until all discs are mounted. Fig xx MDA5 has 6 outerdiscs and 5 innerdiscs. MDA7 has 8 outerdiscs and 7 innerdiscs. MDA10 has 11 outerdiscs and 10 innerdiscs. 5. Grease the seals with Texaco Multifak EP2 or an equivalent grease without solid additives and mount the piston (313). 6. Grease the springs (315) with Texaco Multifak EP2 or an equivalent grease without solid additives. Put the springs on the Brakecover (314). The springs shall be mounted against each other on the inner diameter. 7. Mount the Brake cover (314) on the brake. Oil the screws and assemble the screws. Start mounting by slightly tightening the screws, no more than 1 turn each. Continue with one turn of each screw around the cover. Tightening torque is 114 Nm (84 lbf ft). Table 3.10 Brake Screws (ISO 89811) Spacer MDA 5 MC6S 12x t=54 (2,13) MDA 7 MC6S 12x t=42,4 (1,67) MDA 10 MC6S 12x t=25 (0,98) Draining of Brake cylinder The Diagram 3.1 below shows the falling braking torque M max for increasing pressure in the brake cylinder drain. Example: MDA 10 has a braking torque of Nm / lbf. ft, when the brake is not under pressure and µ = 0,12. Assume that the pressure in brake cylinder drain is 1,5 bar / 21,75 psi. The diagram shows that the actual brake torque (M act ) corresponds to only 90% of M max. Diagram 3.1 Motors with SPECIAL brakes may have different working operation. Please make sure that you check the Ordering code on your brake. % Braking torque Back pressure in brake cylinder drainage line. 30

31 Disassembly of MDA 5, 7 &10. Fig xx Connection 1/4" BSP for flushing of axial bearing 18 Nm / 13 lbf. ft Please read this instruction carefully before starting the disassembly! 1. Start the disassembly by slightly loosening the screws (40). Not more than 1 turn each. Continue with 1 turn of each screw around the cover until the pre-load of the Belleville springs (315)(Cup springs) is zero. After that the screws can be removed and the Brake cover (314) lifted off. 2. The Brake piston (313) can be removed by installing an M12 screw in the centre hole and lifted off by using the screw. Note: The M12 screw can not be used to hold the Brake cover (314) while removing the screws (40). There is a risk that the threaded part in the Brake piston (313) can fail due to big forces when removing the screws. 3. Inner and outer discs (318, 320) can be removed and the screws (43) holding the spacer (3xx) in place can be removed. 4. Loosen the screws (43) holding the Disc centre (302) in place. Please note that the motor cannot be pressurised when the brake assembly is removed. 31

32 Brake MDA 14 & 21 Max external load: 200 kn (44800 lbf) External load: 110 kn (24600 lbf) according to FEM M5: (L2:T5) 27 (1,06) B1 W150x5x30x28x8f DIN 5480 B3 152 H ,00819 ( 5,98 +0,00425) Splines 297 (2x) (11,7) B1 and B2 B2 160,5 144,5 (6,32) (5,69) B3 Flushing connection G 1/8" Brake MDA 14 MDA 21 Motor CA 140 CA 210 Braking torque* Begins to open at** Fully open at** Rec. opening pressure Displ. Max allowed pressure Weight Nm (lbf ft) bar (psi) bar (psi) bar (psi) cm 3 (in 3 ) bar (psi) kg (lbs) (42 000) (60 300) 15 (220) 15 (220) 20 (290) 20 (290) ( ) ( ) 300 (18) 300 (18) 50 (725) 50 (725) 230 (510) 230 (510) * Valid at wet running. Friction coefficient µ = 0,12. Pressure in Brakecylinder = 0 bar (0 psi). Hydraulic oil with AW-additives. ** See diagram

33 Mounting MDA 14 & 21 The brakes, MDA 14 and MDA 21 are mounted to the bracket with M20 (strength class 10.9). Tightening torque 540 Nm (398 lbf ft). Inside of the brake, the spline shaft shall be greased with Texaco Multi fac EP2. The spline shaft shall be filled with oil, if there are external load during rotation. Plug M6 Lifting the MDA 14 & 21 brake Steel eye (x2) with bolt Steel eye bolts (x3) Draining of Brake cylinder The Diagram 3.2, shows the falling static braking torque Nm ( lbf ft) M max for increasing pressure in the brake cylinder drain. Example: MDA 21 has a static braking torque of Nm ( lbf ft), when the brake is not under pressure and µ = 0,12. Assume that the pressure in brake cylinder drain is 1,5 bar / 21,75 psi. The diagram shows that the actual brake torque (M act ) corresponds to only 90% of M max. Diagram 3.2 Motors with SPECIAL brakes may have different working operation. Please make sure that you check the Ordering code on your brake. % Braking torque Back pressure in brake cylinder drainage line. 33

34 Disassembly and assembly of MDA 14 & 21 Please read this instruction carefully before starting the disassembly! 1. Start the disassembly by slightly loosening the screws (40). Not more than 1 turn each. Continue with 1 turn of each screw around the cover until the pre-load of the Belleville springs (315)(Cup springs) is zero. After that the screws can be removed and the Brake cover (314) lifted off. 2. The Brake piston (313) can be removed by installing 3 screws (M8) and be lifted off by using the screws. 3. Inner and outer discs (318, 320) can be removed and the spacer (308) in place can be removed. 4. Loosen the screws (43), and take off the seal retainer (25). 5. Control the seal and mount seal retainer (25) as figure. Oil the screws (43) and assembly with torque 114 Nm (84 lbf ft). 6. Mount spacer for MDA 14 (308). Mount first one outerdisc, then innerdisc, outerdisc until all discs are mounted. N.B Matched disc set. MDA 14 has 8 outerdiscs and 7 innerdiscs MDA 21 has 11 outerdiscs and 10 innerdiscs 7. Grease the seals with Texaco Multifak EP2 or an equivalent grease without solid additives and mount the piston (313) Grease the springs (315) with Texaco Multifak EP2 or an equivalent grease without solid additives, put the springs on the Brake cover (314). The springs shall be mounted against each other in the innerdiameter. 9. Mount the Brake cover (314) on the brake, oil the screws and assembly the screws. Start mounting by slightly tightening the screws, no more than one turn each. Continue with one turn of each screw around the cover, tightening torque is 114 Nm (84 lbf ft) Control of braking torque The motor can be used for controlling the torque for the brake. Start to drain the brake to tank, and increase pressure for the motor until it starts to rotate. Pressure drop over the motor x T s for the motor gives braking torque for the brake. If the motor can not rotate the brake, increase back pressure in the brake cylinder until the motor can rotate the brake. Braking torque = Pressure drop over the motor x motor torque T s x 100/ % Braking torque in diagram 3.1 or 3.2. With full torque and 10 rpm, the brake must not rotate more than max 10 sec. 34

35 Motors with 2-speed valve Mounting of 2-speed valve on CA Motors with 2-speed function must be ordered with correct direction of rotation. With wrong direction, load on the piston will be increased 3 times, which can give overheating of the pistons. With the high pressure supply connected to A- port, the motor shaft rotates in the directions shown by arrows. R-motor rotates clockwise, and L-motor counter-clockwise, wiewed from the motor shaft side. If the motor is working in half displacement, and in not prefered "direction of rotation", allowed pressure is max 210 bar (3000 psi). Fig C P (A-port on motor) 2-speed valve Remove the protective cover from motor mounting surface, place the O-rings (included in delivery) in their proper position on the valve mounting surface. Use grease to keep O-ring fixed. Mount valve against the motor with the ports in corresponding position. 4 pcs 1/2 UNC x 127 (5") included in delivery, strength class 12.9 (ISO 898/1) Tightening torque: 131 Nm (97 lbf ft). *For Marine applications, use Sicaflex or similar for corrosion protection. Fig * Standard 2-speed valve Motor prepared for valve, direction of rotation, Clockwise = R Fig. 3.23a C P (A-port on motor) 2-speed valve Valve S05 must have the sign in this position VTCA 600 will not automatic shift from half to full displacement at overload. Direction of rotation see also page 38. Motor prepared for valve, direction of rotation, Counter-clockwise = L Valve S05 is not allowed with hanging load 35